Insulated door construction



Dec. 2, 1969 J. A. SMART 3,481,388

INSULATED DOOR CONSTRUCTION Filed April 25, 1968 3 Sheets-Sheet 1 Fig ' Jay A. Smarf IN VENTOR.

BY WW Dec. 2, 1969 Filed April 25, 1968 J. A. SMART INSULATED DOOR CONSTRUCTION Fig.4

3 Sheets-Sheet 2 Jay A. Smart INVENTOR.

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Jay A Smart 1 N VENTOR.

a Attorneys United States Patent US. Cl. 160-231 11 Claims ABSTRACT OF THE DISCLOSURE A manner of insulating a folding door formed of a pair of laterally spaced parallel panel assemblies or units. Each panel assembly is made up of a plurality of individual panels hingedly interconnected and adapted, through grooves provided thereon, to receive clip mounted insulation, either individual sheets clip mounted to each panel or a single sheet covering all of the panels and clip mounted to the individual panels. Spring clips are used to mount the insulating sheets without any adhesive bond and in a manner so as to cooperate with the panels in defining an insulating air space.

This is a continuation-in-part of application Ser. No. 563,559, filed July 7, 1966, now abandoned.

The instant invention is generally concerned with folding doors, and more particularly relates to the insulation of such doors in a manner whereby no adhesive bonding of the insulation is required, reliance being had solely upon unique mounting clips engageable with cooperable portions with the panels comprising the door.

It is a primary intention of the instant invention to provide a unique means for insulating folding doors whereby the mounting of the insulation provides, in addition to the insulating properties of the insulation itself, an air space between the individual panels and the insulation. This is basically effected by the utilization of a plurality of spring clips which overlie intermediate portions of the insulation and have the opposite ends thereof spring pressed to locked engagement with the panels of the door. It is contemplated that the spring clips be equally adapted for securing individual insulating sheets or layers to each of the panels, or, as an alternative, to secure portions of a single insulating sheet or layer which overlies all of the panels of a panel assembly or unit. In the latter case, the clips will actually pierce the insulation so as to engage the panels therebeneath. Each of the panels is in itself formed with undercut edge grooves which are uniquely adapted to cooperate with the offset opposite ends of the spring clips so as to provide for a positive locking engagement therebetween, the clips being of a length so as to bow or outwardly bulge between the secured ends thereof and thus allow for a similar outward billowing of the insulation so as to define the desired insulating air cavities or passages.

One of the particular forms of insulation contemplated by the instant invention comprises individual flexible leaded vinyl liners or sheets mounted individually on the separate panels with the opposite edges of each sheet being received within the opposed clip mounting grooves on the corresponding panel. Each of the sheets or insulating liners is of a greater width than the corresponding panel whereby an outward bowing of the liner will be effected so as to provide an effective sound barrier which, through the leaded vinyl liner itself and the intermediate sound trapping and vibration damping cavity, will effectively and substantially completely eliminate sound transmitting vibrations. As will be appreciated, through the utilization of the mounting clips, a quick and positive mounting of the individual liner-s can be 3,481,388 Patented Dec. 2, 1969 quickly effected with the liner automatically assuming an outwardly bulging or billowing configuration so as to provide the effective sound trapping cavity.

Another contemplated form of insulation is primarily a fire insulation in the nature of a liner formed of a compressible layer of fiber glass sandwiched between reinforced cord aluminum foil. This fireproofing liner will span all of the panels comprising one of the panel assemblies and be secured to the individual panels by the spring clips of the instant invention piercing the fireproofing liner and engaging with the subjacent panels. These mounting clips will also bulge outwardly so as to allow for a generally loose positioning of the fireproofing liner against the panels whereby insulating air passages are also defined with these passages permitting a significant cooling convection type draft under actual fire conditions.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout, and in which:

FIGURE 1 is a partial elevational view of a folding door or partition constructed in accordance with the instant invention;

FIGURE 2 is an enlarged partial cross-sectional view taken substantially on a plane passing along line 22 in FIGURE 1 and illustrating one manner of insulation installation in accordance with the instant invention.

FIGURE 3 is a partial cross-sectional view taken substantially on a plane passing along line 33 in FIG- URE 2;

FIGURE 4 is a partial cross-sectional view taken substantially on a plane passing along line 4-4 in FIG- URE 2;

FIGURE Sis a partial perspective view of the upper end of one of the panels with the vibration damping liner mounted thereon;

FIGURE 6 is a cross-sectional view taken substantially on a plane passing along line 6-6 in FIGURE 5;

FIGURE 7 is a partial cross-sectional view taken substantially on a plane passing along line 77 in FIG- URE 5;

FIGURE 8 is an elevational view of one of the door panels with the sound insulating liner of the instant invention mounted thereon;

FIGURE 9 is a perspective view of one of the mounting straps or clips utilized in the embodiment of FIGURES 28;

FIGURE 10 is an enlarged perspective view of a portion of the inner face of one panel assembly illustrating a second manner of insulation in accordance with the instant invention;

FIGURE 11 is a cross-sectional view taken substantially on a plane passing along line 11-11 in FIG- URE 10;

FIGURE 12 is a perspective view of one of the mounting clips particularly to be utilized with the insulation of FIGURE 10; and

FIGURE 13 schematically illustrates the adjacent interconnected at a first end thereof by a suitable jamb (not illustrated), and at the other end thereof by a vertically elongated lead post 18. The lead post 18 is rigidly atfixed centrally along a reduced width end panel 20, the opposite edges of which are operatively engaged, through elongated flexible hinges 14, with a pair of narrow connecting panels 22 which in turn engage, also through the hinges 14, the main partition defining panels 12 of the opposed chamber forming units 16.

Each of the panels 12 is to be formed of an elongated rigid relatively lightweight sound reflective material, preferably heavy gauge extruded aluminum, As will be appreciated from the drawings, each panel 12 includes a body portion having longitudinally extending low angle corrugations 24 extending thereacross and terminating in enlarged edge portions 26. Each of the enlarged edge portions 26 includes, along the full length thereof, an annular groove 28 having a restricted access or mouth 30 thereto. These grooves 28 slidably receive the enlarged or beaded ends 32 of the full length joining hinges 14. Each of the hinges 14 defines a central longitudinal angular portion which assists in properly orientating the panels 12 relative to each other so as to form a generally angular relationship therebetween such as will most effectively reflect and diffuse sound.

In addition to the hinge mounting grooves 28, each panel 12 further includes a pair of aligned inwardly directed substantially full length grooves 34 defined in the enlarged heads 26. These grooves 34 are both located to the same side of the panel 12 and are immediately adjacent thereto with the surface of the central portion of the panel 12 continuing, at the opposite edges thereof, into the adjoining enlarged heads 26 so as to define the circular grooves or recesses 34. The entrance to these liner grooves 34 is restricted by means of an inwardly directed lip 36 positioned from the adjoining panel surface a distance less than the diameter of the groove 34 itself.

The liner 38, which is to define a vibration damping cavity 40 and operate in conjunction with the cavity 40 so as to effectively eliminate sound transmission through vibrations, is preferably to be formed of lead impregnated or filled vinyl, in the nature of a flexible sheet. One such liner 38 is to be associated with each panel 12.

Each liner 38, which is of a length substantially equal to the length of the corresponding panel 12, is to have the opposite longitudinal edges thereof received within the opposed grooves 34, the liner 38 being of a transverse width greater than the transverse distance between the grooves 34 so as to require an outward billowing or cupping of the liner 38 upon a reception of the edges thereof Within the grooves 34. In this manner, the desired cavity 40 is provided between the liner 38 and the panel 12, which cavity 40 is of particular significance in achieving the desired insulating effect, especially in conjunction with the flexible vinyl liner therebehind.

In order to mount the sheet-like leaded vinyl liners 38, use is made of spring steel clips or straps 42 which are of a length approximately equal to the transverse width of the liners 38. These straps, normally positioned approximately three to four feet apart along the length of a panel 12 so as to enable a maximum billowing or cupping of the corresponding liner 38, have the opposite ends thereof positioned within the opposed grooves 34 of the corresponding panel 12 in overlying relation to the liner 38, the straps 42, in light of the length thereof, bowing outwardly. The resiliency in each of the straps 42 is such so as to fixedly retain the strap with the ends thereof engaged in the opposed grooves 34, and at the same time fixedly retain the liner 38 upon a springing of the clips 42 into position. It will be noted from FIGURES 6 and 9 that each clip, on the opposed ends thereof, includes a laterally outwardly directed portion or bead 44. These portions 44 lie against the inner surfaces of the recess lips 36 and act so as to further positively retain the ends of the clip 42, while at the same time allowing for a maximum outward bowing thereof which in turn enables a maximum flaring of the liner 38. In introducing the opposed ends of each of the mounting clips or straps 42, it will be appreciated that a slight compressing of the liner 38 will be effected at the edges thereof, the inherent resiliency of the material of the liner 38 making this possible and also tending to effect a retention of both the liner and the clip within the groove provided therefor.

Referring again to FIGURE 2, it will be noted that the end panel 20 and the two connecting panels 22 are also provided with clip mounted liners 46, which are similar in construction, orientation and function to the liners 38.

With reference to FIGURES 3 and 4, it will be noted that a compound header 48 is to be utilized in conjunction with the pair of door defining units 16. The header 48 is to include a pair of overhead tracks 50, only one of which has been specifically illustrated, with each track 50 rollably mounting, through mounting elements 52, one of the units 16 for holding and unfolding movement therealong. In addition, it will be noted that the headers 48 are specifically provided with sound deadening materially 54 so as to reduce to a minimum any sound transmission therethrough, and thereby cooperating with the sound insulating units 16 themselves in providing the desired insulating effect.

Attention is now specifically directed to FIGURES 10-13 wherein another insulation embodiment, using generally the same mounting system described supra, has been illustrated. This embodiment is primarily concerned with fireproofing or fire insulating and utilizes an insulating sheet or liner which extends along and is of substantially equal height with the entire panel assembly 16, one such liner 60 being mounted on each of the two assemblies or panel units 16 which comprise the door 10'. The liner 60 itself includes an internal expanded and compressible layer of fiber glass 62 sandwiched and confined between two outer layers of cord reinforced aluminum foil 64. The liner 60 is secured to its corresponding panel assembly 16 by means of spring steel clips 66 which are quite similar in construction and use to the clips 42. The basic difference between the clips 66 and the clips 42 reside in the provision of tapered end portions 68 on the clips 66 so as to enable a ready penetrating of the liner 60 as suggested in FIGURES 10 and 11. The extreme ends 70 of the clips 66 are, similar to the clips 42, laterally outwardly bent or directed so as to engage with-in the opposed grooves 34 inward of the lips 36 while allowing for the maximum outward bowing of the clips 66.

The clips or straps 66, mounted between two and four feet apart, are each of a length so as to bow outwardly upon an engagement of the opposite ends thereof within the opposed grooves 34 with the resilient nature of the clips themselves being sufficient so as to rigidly retain the clips and the received portions of the liner 60. In addition, because of the bowed nature of the mounted clips 66 and the generally compressible nature of the liner 60, in conjunction with the corrugated configuration of the panels 12 themselves, full height insulating air spaces 72 will actually be formed between the liner 60 and the underlying panels 12.

Noting FIGURE 13, under actual test conditions, it has been found that upon the subjecting of the outer face A of one assembly 1 6 to a continued application, up to two hours, of flame heat 74 of 2600 F., the panel 12 against which the flame was directed achieved a maximum temperature of only 1360 F. while the inner face B of the insulation on the fired panel 12 recorded a maximum of 600 F. Finally, the unfired second panel recorded a maximum temperature of 194 F. In other words, upon insulating a door of a thickness compatible with con ventional folding doors with the insulating system of FIGURES 10-13, it will still be possible to touch one surface of the door without being burned when a continned application of heat up to at least 2600" is being applied to the other side of the door.

Further, it was noted, because of the air passages or spaces formed by the liner 16 in the manner of mounting the liner, a substantial movement of air or draft was created as a result of convection upon the application of heat to the outer face of one of the panel assemblies. It was this movement or circulation of air inward of the panels which contributed significantly to the drastic temperature drop noted, the fired panel itself, notwithstanding the fact that the panel would normally melt at 1600 F., surviving the application of a flame at 2600 F. and sustaining no damage other than a destroying of the surface finish thereon.

One other point of particular significance with regard to the use of the liner 16 including the outer reinforcing layers of cord reinforced aluminum is that should the vinyl hinges 14 be destroyed, as will occur under extremely high temperature conditions, the liner 60 will itself automatically act as a hinge and hence retain the door completely operable and in continuing use as an effective fire barrier. In this manner, a highly effective fire barrier is provided notwithstanding the basic lightness of the door construction and the ease with which it can be manipulated.

From the foregoing, it will be appreciated that a highly unique manner of insulating a folding door has been set forth, such being equally adaptable for both sound and fireproof insulating, as well as for that matter any other appropriate type of insulating wherein sheets or liner type insulating materials are to be mounted either on the individual panels or on an entire panel assembly. In addition, the mounting of the insulation is effected without requiring the use of any adhesive bonding or the like, reliance being had simply upon quickly mounted spring clips which cooperate with specifically formed portions of the underlying panels so as to both mount the insulation and do so in a manner whereby highly desirable insulating air spaces or cavities are provided. Such cavities are of significance in sound insulating in that a means for effectively damping vibrations is provided, those insulated doors wherein the insulation is bonded intimately to the door panel providing substantially no barrier to the transfer of sound by vibrations. With regard to fireproofing, the provision of internal cavities enables an actual air movement between the insulation and facing panel, normally of a heavy gauge aluminum, which contributes significantly to the desired heat loss.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invent-ion to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention as claimed.

What is claimed as new is as follows:

1. In an insulated partition, a rigid panel, a flexible liner overlying one face of said panel, said panel comprising an intermediate portion and a pair of opposed parallel edges, said parallel edges being enlarged along a substantial portion of the length thereof, each of said enlarged edges defining a first outwardly directed bead receiving groove generally opening away from said intermediate portion, and a second inwardly directed groove positioned laterally of the intermediate portion and opening generally toward the equivalent groove on the other enlarged edge, and an elongated mounting clip overlying said liner and having opposed ends engaged frictionally within the inwardly directed opposed grooves on the opposed enlarged panel edges, said clip being resilient and slightly bowed over the received liner with the resiliency of the clip maintaining the locked engagement of the opposed ends thereof, said liner being at least partially spaced from said panel along the full length thereof so as to define an air passage therebetween.

2. The construction of claim 1 wherein each of said inwardly directed grooves includes a lip portion restricting the access thereto, the opposite ends of said clip being laterally offset and engaged behind said lips.

3. The construction of claim 2 wherein said liner comprises a sheet having opposed edges and being of a width greater than the distance between said inwardly directed grooves, the opposed edges of said sheet being engaged within said inwardly directed grooves with the sheet bowing outwardly therebetween and generally conforming to and being retained by the bowed clip.

4. The construction of claim 1 wherein said liner comprises a sheet having opposed edges and being of a Width greater than the distance between said inwardly directed grooves, the opposed edges of said sheet being engaged within said inwardly directed grooves with the sheet bowing outwardly therebetween and generally conforming to and being retained by the bowed clip.

5. The construction of claim 4 wherein said flexible liner sheet comprises a lead containing plastic sheet having substantial sound insulating properties.

6. An insulated folding door construction comprising at least one panel assembly including a plurality of vertically elongated hinge interconnected panels, flexible liner means overlying one face of said assembly, a plurality of resilient clips engaged over portions of said liner means, each of said clips having opposed ends thereof engaged with an underlying panel, each clip bowing outwardly between the engaged ends thereof and allowing a. similar outward bowing of the liner means so as to define an air space between the liner means and an underlying panel, each of said panels including receiving portions therein receiving and retaining the opposed resiliently loaded ends of one or more of said clips.

7. The construction of claim '6 wherein said liner means comprises a single elongated sheet overlying substantially the entire assembly, said mounting clips having the opposed ends thereof engaged through said liner, said mounting clips, when engaged with said panels, constituting the sole securing means for said liner means.

8. The construction of claim 7 wherein said liner means is defined by a fiber glass core sandwiched between a pair of reinforced flexible aluminum layers.

9. The construction of claim 8 wherein said folding door construction includes a second panel assembly interconnected in laterally spaced relation to said first panel assembly for synchronized movement therewith, said second panel assembly also including a clip mounted flexible liner defined by a fiber glass core sandwiched between a pair of reinforced flexible aluminum layers, the liner means on the second panel assembly being similarly outwardly bowed so as to define an insulating air space, said air spaces enabling a vertical movement of air between each liner means and the adjacent panels upon the heating of the air.

10. In a fire insulating door, a pair of laterally spaced parallel interconnected folding panel assemblies, each of said panel assemblies including a plurality of vertically elongated hingedly connected metal panels, a flexible liner of fire insulating material overlying the inner face of each panel assembly and being fixedly movable therewith, means securing each liner to the associated panel assembly at spaced points, each of said liners, between the secured space points, being spaced generally from the associated panel assembly so as to define air passages therebetween for the movement of air therethrough, said passages generally opening through the upper and lower ends of said panel assemblies.

11. The construction of claim 10 wherein said liners are secured in a non-adhesive manner, utilizing spring clips engaged about portions of each liner and releasably locked to the underlying panel assembly.

(References on following page) References Cited UNITED STATES PATENTS 3,277,952 10/1966 Tsuharo 160-183 X 3,223,147 12/ 1965 Holloway.

Kuehne 52407 X PETER M. CAUN, Primary Examiner Maurer 18133.1

Brooks 52-407 5 US. Cl. X.R. Spencer et a1. 52-489 X King at a] 181 33'1 16084, 206, 236; 18133.1 

